Beveled angle fiber optic connector

ABSTRACT

A fiber optic connector in which first and second optical fibers are aligned at a fiber interface of the connector. The first optical fiber has a beveled angle end face, and the second optical fiber has a complementary beveled angle end face. Abutting connector members are joined in a connector enclosure which enables the respective fiber end faces to abut at an angle at the fiber interface. The respective fiber end faces are joined at a vertical aligned position for the connector, also at a horizontal aligned position for the connector. Suitable alignment means provided on the connector members enable alignment of the fiber end faces at the fiber interface. In a fixed aligned position of the assembled connector, the respective fiber end faces are held in abutting and full engagement at the fiber interface, in which the vertical aligned position of the optical fibers in the connector is coincident with the horizontal aligned position thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a fiber optic connector, andspecifically to a fiber optic connector that aligns optical fibersmounted in one portion of the connector with optical fibers mounted inanother portion of the connector.

2. Description of the Prior Art

Optical fibers are often used for data transmission because of theirwide bandwidth and capacity for carrying data in the form of lightsignals that are unaffected by electromagnetic fields. However, onedrawback to the use of optical fibers is the difficulty involved inproperly connecting two optical fibers at a connector. Signal losses inthe transfer of data across an interface between optical fibers in aconnector can cause substantial problems in the transfer of data. If theabutting optical fibers are not properly aligned, a substantial portionof the signal can be lost at the interface. Proper alignment of theoptical fibers to minimize signal losses is difficult, because thesefibers typically have a diameter comparable to that of a human hair. Anymisalignment of the fibers at their interface in the connector can causelight signals transmitted along one optical fiber to be absorbed by acladding that surrounds the second optical fiber. As a result, asubstantial portion of the signal conveying data along the opticalfibers can be lost, thereby increasing the risk of data loss.

U.S. Pat. No. 4,695,126 shows a connector in which a pair of opticalfibers form an angle where their ends meet. This angled interface isused for both reducing reflections and providing mechanical registrationof the ends of the abutting optical fibers. However, if one portion of aconnector is repeatedly connected to and disconnected from anotherportion of the connector, means must be provided to enable the repeatedand precise alignment of the abutting ends of the optical fibers. Thispatent does not disclose how such repeated alignment can beaccomplished.

Besides aligning the optical fibers in their respective connector parts,a connector must ensure the quality of the interface between the opticalfibers. For example, it is desirable to maximize the force of contact atthe interface between their abutting ends. Any offsets, incongruities,or other defects occurring at the interface can substantially impair thequality of data transmission through the connector. Further, the needfor consistent and accurate alignment of the respective fibers disposedin opposite portions of the connector is substantially complicated bythe requirement the different mating connector portions be readilyinterchangeable with similar connector portions.

In a specific application of this data transmission technology, anoptical fiber connector is required that includes a non-disposablemember in which one or more generally parallel optical fibers aredisposed. This connector member must connect with a complementarydisposable member in which a corresponding number of generally paralleloptical fibers are mounted. When the connector members are assembled,the optical fibers in the non-disposable member must intimately contactand be substantially aligned with the complementary optical fibers inthe disposable member.

Such a connector is intended for use in a hospital environment, toconvey data from a sensor to a processing apparatus that is part of apatient monitoring system. The non-disposable member of the connector isassociated with a data line connected to the patient monitoring system,and a disposable member of the connector is connected to the sensor,which is inserted into a patient's cardiovascular system. It iscontemplated that the monitoring system may be used with a number ofpatients, e.g., the monitor may stay with a single patient until itsintended use is completed and then disconnected from that patient andconnected to a second patient through the disposable member of adifferent connector.

Furthermore, it may be necessary to move a patient connected to amonitoring system from one room to another, and it may be undesirable tomove the monitoring system associated with that patient. Accordingly, itmay be necessary that the patient be disconnected from the firstmonitoring system and reconnected to a second monitoring system locatedin another hospital room.

Realistically, the critical dimensions of the connector members may varywithin manufacturing tolerances. It would thus be highly desirable toprovide a connector design that enables the optical fibers in thenon-disposable member to precisely align with and fully contact theoptical fibers and the disposable member at the interface of theconnector, with each and every connection, regardless of any smallvariation in the critical dimensions of the connector members.

Therefore, it is desirable that variations due to manufacturingtolerances in the connector members be accommodated to assure that theoptical fibers mounted in the respective non-disposable and disposablemembers are substantially aligned whenever there is a completedconnection. Such alignment cannot rely on the matching of a specificpair of non-disposable and disposable members of the connector. Further,it would be desirable to provide specific alignment means to positivelyalign the optical fibers of the non-disposable member of the connectorwith those of the disposable member of the connector, both horizontallyand vertically, to minimize any offset of the respective optical fiberswhen the connector is assembled. It would also be desirable to modifythe abutting faces of respective optical fibers disposed on oppositesides of the connector interface, to minimize incongruities therein.Such modification should maximize contact of the complementary opticalfibers at the interface of the two connector members.

Because of the extreme fragility of the optical fibers, it would bedesirable to provide wear surfaces to minimize wear on critical portionsof the connector members during the engagement and alignment of thedisposable and non-disposable members of the connector. It would furtherbe desirable to provide means for electrically connecting conductorsthat are mounted in the disposable and non-disposable members of theconnector. Disposable and non-disposable members of the connector shouldlock in a fixed, aligned position when engaged.

SUMMARY OF THE INVENTION

In accordance with the present invention, a fiber optic connectorincludes one or more first optical fibers and one or more second opticalfibers, each first optical fiber having a complementary beveled endface, the respective first and second fiber end faces abutting eachother at an angle at a fiber interface. Means are provided for aligningeach first optical fiber with its respective second optical fiber at theinterface of th fiber optic connector.

A non-disposable member of the connector includes a front face whichholds a beveled end face of one or more first optical fibers mountedtherein. A disposable connector member includes a front face which holdsa complementary beveled end face of one or more corresponding secondoptical fibers mounted therein.

A vertical reference surface associated with the first optical fibers iscooperative with a vertical reference node associated with the secondoptical fibers to define a vertical aligned position for the respectivefiber end faces at the fiber interface.

A horizontal reference surface associated with the first optical fibersis cooperative with a horizontal reference node associated with thesecond optical fibers to define a horizontal aligned position for therespective fiber end faces at the fiber interface.

The fiber optic connector also includes forward alignment means providedin the disposable member which serve as wear surfaces to protect the endfaces of respective abutting optical fibers disposed in thenon-disposable and disposable connector members. In addition, theconnector includes means for electrically connecting the non-disposablemember to its complementary disposable member.

The respective horizontal and vertical alignment means assure that therespective optical fibers will be precisely and accurately aligned, thatsuch alignment will occur with a minimum of wear, repeatedly andaccurately, independent of any manufacturing tolerances associated withthe non-disposable and disposable members of the connector.

These and other advantages will be better understood when the drawings,described briefly below, are considered with the detailed description ofthe preferred embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the fiber optic connector ofpresent invention disposed in an assembled position an optical modulefor the connector;

FIG. 2 is an exploded perspective view of the optical module and thefiber optic connector with a non-disposable member of the connector anda disposable member of the connector separately shown, with certainparts not shown;

FIG. 3 is a top right perspective view of the non-disposable member ofthe connector of the present invention with a portion thereof brokenaway to better illustrate its configuration;

FIG. 4 is a bottom right perspective view in which the non-disposableconnector member of FIG. 3 is rotated 180° to show the bottom thereof;

FIG. 5 is a top perspective view taken from the rear of thenon-disposable member of FIG. 3;

FIG. 6 is a perspective view of a fiber optic cable assembly associatedwith the non-disposable member shown in FIG. 5;

FIG. 7 is a top perspective view of the disposable member of the fiberoptic connector of the present invention, with a cover of the disposablemember removed;

FIG. 8 is a cut away perspective view of a portion of the disposablemember, rotated in respect to the view of FIG. 7;

FIG. 9 is a top plan view of the disposable member shown in FIG. 7;

FIG. 10 is a side sectional view taken along line 10--10 of FIG. 1;

FIG. 10 is the detail A--A of FIG. 10;

FIG. 10B is the detail B--B of FIG. 10;

FIG. 11 is a top perspective view of the cover of the disposable memberof the fiber optic connector shown in FIG. 7;

FIG. 12 is a cut away top perspective view of a portion of the cover,for the disposable member, rotated in respect of the view in FIG. 11;and

FIG. 13 is a cut away perspective view of a portion of the cover of FIG.11, rotated 180° to show the bottom thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

An optical fiber connector enclosure 20 is shown in FIG. 1 with theimproved fiber optic connector 40 of the present invention disposedtherein in assembled relation. In FIG. 2, the connector enclosure 20 andthe fiber optic connector 40 are shown in an exploded view which betterillustrates the respective parts of the fiber optic connector which aredescribed in greater detail below.

The connector enclosure 20 includes a main body portion 22 that isgenerally rectangular in shape but includes a necked-down portion 24 atan outer end thereof as shown in FIG. 2. Relatively thick lateral sidewalls 25 and 26 and a substantially thicker end wall 28 define a spacetherein for receiving the fiber optic connector 40.

The fiber optic connector 40 includes a non-disposable portion or member42 and a disposable portion or member 44, the disposable member having acover 46. An enclosure cover 29 overlies the main body portion 22 of theconnector enclosure 20 when the connector 40 is in place.

Facing slots 31 and 32 are disposed in the respective inner faces oflateral side walls 25 and 26 of the main body portion 22 of theconnector enclosure 20. The slots 31 and 32 are disposed near thenecked-down portion 24 of the main body portion 22 and extend below theupper surface of a base wall 34 of the main body portion. A transverseslot 35 in the base wall 34 connects the side slots 31 and 32.Projecting forwardly of the transverse slot 35 are a pair of slots 37,each disposed adjacent a respective sidewall 25 and 26. The slots 37each pierce the base wall 34 at their respective intersections with thetransverse slot 35. Disposed forwardly of the slots 37 and generally inalignment therewith are a pair of electrical contacts 38 (FIG. 10). Eachcontact 38 includes a washer 38a and a screw 38b (FIG. 10B). A baseplate 39 covers the bottom of the connector enclosure 22.

The non-disposable member 42 of the connector 40 is U-shaped as shown inFIGS. 3-5 and includes a base 43 with legs 45 extending forwardly fromopposite ends of the base. The base 43 is substantially thicker than thelegs 45. However, the non-disposable member 42 is a plastic molded partand its interior is substantially hollow with the periphery of the base43 defined by relatively thin opposite side walls 43a, 43b and oppositeend walls 45a and 45b. An outer end 47 of the base 43 opens into theinterior of the member 42. A peripheral flange 48 surrounds an openingin the outer end 47 of the hollow base 43. Stiffeners 47a are providedbetween sidewalls 43a,b in the hollow interior of the base 43. An angledinner or front wall 49, generally disposed between legs 45 of theU-shaped non-disposable member 42, completes the base 43.

Legs 45 extend generally transversely from the base 44, in generallyparallel alignment, at opposite ends thereof. The outer side portions oflegs 45 are defined by forward extensions of opposite side walls 43a,bof the base 43 and the end walls 45a,b. Respective interior side walls45c, extend forwardly from the front wall 49 of the base 43, to definerespective inner side portions of the legs 45. Forward end walls 45denclose the legs 45.

At one side of the front wall 49 of the base 43 is a forward extensionor pad 50, disposed between the respective forward portions of legs 45and supported by angled side walls 50a and angled top and bottom walls50b, the walls 50a,b extending forwardly from the front wall 49. Thewalls 50a and 50b project forwardly to define an elevated abutmentsurface or front face 51 of the pad 50 that is somewhat smaller than thearea defined by the pad on the front wall 49. Three equally spaced andcentrally located openings 52, provided in the front face 51 of the pad50, receive forward ends 53a of respective optical fibers 53 associatedwith a cable assembly 55. Both the front wall 49 of the base 43 and thefront face 51 of the pad 50 on the front wall are canted at about 20°from the vertical or 70° from the horizontal when the non-disposablemember 42 of the fiber optic connector 40 is positioned in the main bodyportion 22 of the connector enclosure 20. The angle of 20° chosen forthe preferred embodiment should be considered illustrative and notlimiting. The intent is to minimize a reflective component of light atthe fiber interface. Each opening 52 receives a glass optical fiber 53,which in the preferred embodiment is about 0.0096 inches in diameter(0.0096D), or about 2 to 3 times the diameter of a human hair.

In FIG. 3, the non-disposable member 42 of the connector 40 is shownlying on its bottom face. On the underside of the non-disposable member42, as shown in FIG. 4, transverse lateral ribs 56 extend forwardly fromthe base 43 of the member 42 along the legs 45 to terminate nearrespective end walls 45d thereof.

The pad 50 is slightly narrower than the front wall 49 of the base 43.However, on each side of the pad 50, at the front wall 49 of the base43, inner side wall 45c of each leg 45 of the non-disposable member 42is notched or stepped to define respective horizontal reference surfaces57a and 57b and respective vertical reference surfaces 58a and 58b inopposite side walls 45c in the respective inner portions of legs 45. Thereference surfaces 57a,b and 58a,b are associated with the opticalfibers 53 mounted in the openings 52 in the pad 50 and are provided toprecisely align the optical fibers 53 in the non-disposable member 42with their counterparts in the disposable member 44, as well as toconstrain respective lateral and vertical motion of the disposablemember relative to the non-disposable member.

An inner step or notch 59 on each inner sidewall 45c defines a lateralreference surface 57a,b that is generally parallel with its respectiveinner side wall 45c, but stepped toward its respective outer side wall45a or 45b. Vertical reference surfaces 58a,b extend inwardly fromrespective upper ends of reference surfaces 57a,b to intersectrespective inner side walls 45c generally at a midplane thereof.

The notches 59 do not extend vertically from the front face 49 of thebase 43 to the front ends 45d of the legs 45, but rather are cantedtowards the outer side walls 45b of the legs from about the mid point ofthe notch to the front ends of the legs to provide respective taperedguide surfaces 60 in respective outer legs of the non-disposable member42. Also, the respective intersection of lateral reference surfaces 57aand 57b, vertical reference surfaces 58a and 58b, and the respectiveinner ends of the canted portions 60 ar also rounded to guide thedisposable member 44 into the non-disposable member 42 of the connector40.

As shown in FIGS. 7-9, the disposable member 44 of the connector 40 is amolded plastic part having a hollowed-out main body portion 60 ofgenerally trapezoidal shape. The hollowed-out main body portion 60 has arear wall 61 that is longer than a front wall 62, with side walls 63extending generally transversely from opposite ends of the rear wall 61to slightly beyond their respective midpoints. At these mid-points, theside walls 63 bend inwardly toward the narrow front wall 62 to define anecked-down portion 64 of the disposable member 44, disposed at a frontend of the main body portion 60.

The main body portion 60 features a double walled construction in whichthe rear wall 61 and opposite sidewalls 63 include respective innerwalls 61a and 63a, which are about 0.070 inches lower than outer walls61 and 63. The front wall 62 is of single wall construction, but theupper surface thereof coincides with the respective upper surfaces ofwalls 61a and 63a, for reasons to be described below.

A base wall 65 of the main body portion 60 features a relatively largecentral cutout portion 66 which is bisected by a cross member 67. Crossmember 67 extends from the bottom of the necked-down portion 64 of themain body portion 6 and relatively parallel to the transverse portionsof sidewalls 63, terminating about 0.200 inches outside the rear wall61. The height of the cross member 67 approximately equals the height ofthe inner walls 61a and 63a.

The extension of cross member 67 between the rear wall 61 and thenecked-down portion 64 partially defines a pair of openings 68 and 69 inthe base wall 65 of the main body portion 60. The cross member 67includes a channel 67a between opposite channel side walls 68a and 69a,which also respectively correspond to the inner walls of the openings 68and 69. Respective outer side walls 68b and 69b extend transversely fromthe rear wall 61 to the respective inwardly tapered portions of thesidewalls 63 to define one side of the openings 68 and 69, with theforward ends of inner walls 68a and 69a curving outwardly to engagerespective side walls 63 at the respective inwardly directed portionsthereof to form openings 68 and 69 in the base wall 65.

Extending inwardly from the rear wall 61 into the openings 68 and 69 arerespective longitudinal projections or contacting fingers 70 and 71.Fingers 70 and 71 are generally coincident with base wall 65 and extendinwardly to terminate near the upper end of respective openings 68 and69.

Members 73a and 73b project upwardly from the base wall 65 in thenecked-down portion 64 of the main body portion 60 to extend slightlyabove front wall 62 and side walls 63a and are generally aligned withthe main portions of respective side walls 68a and 69a of the crossmember 67. Front wall 62 is relatively thick and is canted at an anglethat is complementary to the angle of the front wall 49 of the base 43on the non-disposable member. The upper surface of the front wall 62 isflush with the respective upper surfaces of the inner walls 61a and 63aof the main body portion 60.

Three centrally located, equally spaced support members 74 projectoutwardly from the upper end of the front wall 62 and each has definedtherein a central slot 75. Three discrete plastic optical fibers 80,each about 0.0046 inches in diameter (0.0046D), or aboutone-and-one-half times the diameter of a human hair in the preferredembodiment of the present invention are associated with a fiber opticcable assembly 76, and are each received in a respective slot 75.

At the forward end of a first side wall 63, on an outer face thereof,and generally aligned with front wall 62, is molded a first lateralreference node 78, which is wedge-shaped and generally incompressible.At the forward end and on the outer face of an opposite side wall 63, ismolded a second lateral reference node 79, generally compressible,comprising a triangular "crush" rib. Nodes 78 and 79, disposed atopposite ends of the front wall 62 and generally aligned therewith, arecomplementary with the horizontal reference surfaces 57a,b provided inopposite side walls 45c of the non-disposable member 42.

Also, at the forward end of each outer side wall 63, on an upper surfacethereof, is molded an incompressible vertical reference nodule 63b. Eachnodule 63b is disposed at an opposite end of the front wall 62 andgenerally in alignment therewith. Vertical reference nodules 63b arecomplementary to the vertical reference surfaces 58a,b provided inopposite side walls 45c of the non-disposable member 42.

Connected to the outside of the rear wall 61 of the main body portion 60is an integral plastic spring 82 having a pair of rearwardly extendingflexible members 81 disposed on opposite sides of the cross member 67.Flexible members 81 terminate at a forward edge of a spring handle 83.Spring latching members 84 are provided at an inner end of the handle83.

Overlying the main body portion 60 of the disposable member 44 is agenerally L-shaped cover 46 (FIGS. 11-13) having a base wall 91, whichis inserted between outer walls 61 and 63 to overlie the main bodyportion 60, resting on the upper surfaces of inner rear wall 61a, innerside walls 63a and front wall 62. Overlying members 73a and 73b is a cutout 91a provided on the underside of base wall 91. Cut out 91a providesclearance for the members 73a,b, which protrude slightly above sidewalls 63a, extending into the cutout 91a.

An upright leg 95 of the L-shaped cover 46 also supports a rearwardprojection 96, which overlies the rearward extension of the channel 67from the rear wall 61 of the main body portion 60. At the front end ofthe cover 46, three centrally located, equally spaced inner projections97 complement and engage the support members 74 when each optical fiber80 of the cable assembly 76 has been placed in its respective slot 75.Inner projections 97 thus trap and hold the optical fibers 80 in a fixedposition for alignment with the complementary optical fibers 53 in thenon-disposable member 42. Disposed on opposite sides of the projections97 are extensions 98, each of which have a front face 98a that isgenerally coplanar with respective front faces 97a on the innerprojections 97.

Both the fiber optic cable assembly 55 (FIG. 6) associated with thenon-disposable member 42 of the connector 40 and the fiber optic cableassembly 76 (FIG. 7) associated with the disposable member 44 aremulti-strand cable assemblies and include several similar structuralelements. However, their differences are significant and thosedifferences offer an important contribution to the effectiveness of thefiber optic connector of the present invention. Accordingly, fiber opticcable assemblies 55 and 76 are discussed separately below.

The optical cable assembly 55, associated with the non-disposable member42 of the connector 40 comprises a plurality of elongated, discrete,glass optical fibers 53. Although the fiber optic connector 40 of thepresent invention is not limited to a specific combination of sizes forthe respective optical fibers 53 and 80, each of the optical fibers 53of the preferred embodiment is about 0.0096 inches in diameter(0.0096D). A plurality of elongated Kevlar elements 101 are co-extensivewith the optical fibers 53 to provide tensile strength to the cableassembly 55 and thus protect the relatively fragile optical fibers 53,and a pair of elongated thermocouple elements 102 co-extensive with theoptical fibers 53 are included in the cable assembly 55 for temperaturemeasurement. The thermocouple elements 102 are metallic.

The cable assembly 55 is connected to the non-disposable member 42 ofthe connector 40, as follows.

The optical fibers 53, the Kevlar elements 101 and the thermocouplewires 102 are separated before assembly, with the optical fibers 53being suitably secured into the openings 52 provided in the front face51 of the pad 50. The optical fibers 53 are then bonded in place with arespective front face 53a of each optical fiber protruding slightlyforward of front face 51 of pad 50. A suitable potting material isapplied to fill the hollow interior of the non-disposable member 42,anchoring the optical fibers 53 in place.

The front face 51 of the pad 50 is then lapped with a suitable lappingtool that cants as well as smooths the front face and also grinds therespective front face 53a of each optical fiber 53 disposed therein sothat it is flush with the front face. Both the front face 51 of the pad50 and the front faces 53a of the optical fibers 53 are canted to aprecise angle that is 20° from the vertical as shown in FIG. 2. Thisdesign also allows the angle to be reduced to at least 15°. Once thefront face 51 and the optical fibers 53 therein have been lapped tosmooth the respective faces thereof and to produce the desired angle,the non-disposable portion 42 of the connector 40 is inserted into theconnector enclosure 20 as follows.

With cable assembly 55 in place, the non-disposable member 42 of theconnector 40 is mounted in the main body portion 22 of the connectorenclosure 20. The respective side flanges 48a of the peripheral flange48 are disposed in the slots 31 and 32 provided in the sidewalls 25 and26 of the main body portion 22. A lower flange 48c is received withinthe slot 35 provided in the base wall 34, and lateral ribs 56 runningalong legs 45 of the non-disposable member 42 are received incorresponding complementary slots 37 in the base wall.

A registration nodule 48b (FIG. 5) is provided at the midpoint of eachside flange 48a. Nodule 48b extends outwardly thereof and engagesopposite edges of a respective slot 31,32 to precisely position thenon-disposable member 42 in the enclosure 20. The engagement of thelower flange 48c within the transverse slot 35 defines a precisevertical location for the non-disposable member 42 in the connectorenclosure 20. With the non-disposable portion 42 fixedly mounted in theconnector enclosure 20, the remaining portions of the cable assembly 55are connected thereto as follows.

The slots 37 cut in the base wall 34 of the connector enclosure 20undercut the transverse slot 35 at the respective intersections thereof,providing openings in the base wall 34 which enable the thermocouplewires 102 to access the underside of the connector enclosure 20. Thusthermocouple wires 102 can connect to the undersides of contacts 38. Asuitable channel 25a is provided in the sidewall 25 to enable the Kevlarelements 101 to be drawn away from the cable assembly 55 and bonded tothe connector enclosure 20.

The optical cable assembly 76 (FIG. 7), associated with the disposablemember 44 of the connector 40 includes a plurality of elongated,discrete plastic optical fibers 80, each of which is about 0.0046 inchesin diameter (0.0046D). A plurality of elongated Kevlar elements 101'coextensive with the optical fibers 80 provide tensile strength to thecable assembly 76, and thermocouple wires 102' are included to providetemperature measurements. The optical fibers 80 of the disposable member44 are not limited to the dimensions recited in the preferredembodiment, but should be somewhat smaller in diameter than the opticalfibers 53 of the non-disposable member 42 to minimize signal loss at theinterface of the optical fibers in connector 40.

To connect the cable assembly 76 to the disposable member 44, the Kevlarelements 101' are separated from the optical fibers 80, and each opticalfiber 80 is secured in a respective slot 75, preferably by bonding it inplace. The Kevlar elements 101' are drawn into a shallow channel 61a' tobe bonded therein. The channel 61a' is adjacent the channel 67a,disposed in an upper face of the rear wall 61 of the disposable mainbody portion 60. Thermocouple wires 102' extend along the channel 67auntil they reach respective cutout portions 68a' and 69a' provided inthe respective sidewalls 68a and 69a of the channel 67a, with a firstwire 102a' to be inserted into a pair of openings 70a in the inner endof contacting finger 70 and a second wire 102b' to be inserted into apair of openings 71a in the inner end of contacting finger 71.Thermocouple wires 102a', 102b, are threaded through respective openings70a and 71a and extend to the underside of the disposable member 44,respectively defining electrical contacts 103a and 103b at the undersideof the disposable member.

Projections 73a and 73b, provided in the necked-down portion 64 of themain body portion 60, separate the optical fibers 80 as they extendalong the channel 67a into the slots 75 so as to avoid undue bending ofthe optical fibers 80 when they are placed in the slots 75. With theoptical fibers 80 bonded in place in the slots 75, with the electricalcontacts 103a and 103b appropriately connected to the disposable member44, and with the Kevlar elements 101' suitably bonded to the main bodyportion 60 of the disposable member 44, the cover 46 is suitablyaffixed, preferably by bonding it to the main body portion 60 of thedisposable member 44.

With the cover 46 in place, the front faces of the support members 74,and the front faces of the associated optical fibers 80 mounted thereinare lapped to produce a smooth angular face 74a for each support member74 and a smooth, angular, coplanar face 80a for each of the opticalfibers 80 of the disposable member 44. The lapped angle is complementaryto the 20° angle lapped onto the end faces 53a of the optical fibers 53disposed in the end face 51 of the non-disposable member 42 of theconnector 40. Only the end faces 74a of the support members 74 and theirassociated optical fibers 80 are lapped. The inner projections 97 on thecover 46 are not lapped. However, because the front face of each forwardextension 98 does not overlie a corresponding support member, a portionof each forward extension 98 coplanar with the front faces 74a ofsupport members 74 is lapped. Thus, a forward edge is defined on theextensions 98 that is coplanar with end faces 80a of the optical fibers80 which are disposed in and slightly forward (0.002") of respectivelapped end faces 74a.

The completed disposable member 44 of the fiber optic connector 40includes the lapped end faces 80a of the optical fibers 80 and acompletely installed cable assembly 76. The assembled disposable member44 can then be inserted into the connector enclosure 20 as follows.

Opposite lateral reference surfaces 57a, 57b provided on the insidewalls 45c of legs 45 of the U-shaped non-disposable member 42 engage thecomplementary lateral guide member 78 and the crush rib 79 associatedwith the disposable member 44 to laterally align the end faces 80a ofthe plastic 0.0046D) optical fibers 80 in the disposable member 44 withthe end faces 53a of the glass (0.0096D) optical fibers 53 in thenon-disposable member. Forward extensions 98 engage the outer edges oflapped face 51 of the pad 50 to traverse the lapped face as thedisposable member 44 is inserted into the connector enclosure 20.

At the end of travel of the extensions 98, reference nodules 63bprovided at the upper end faces of sidewalls 63 of disposable member 44engage the vertical reference surfaces 58a, 58b defined in the notches59 provided in the side legs 45 of the non-disposable member 42. Therespective end faces 53a of the optical fibers 53 mounted in thenon-disposable member 42 are both laterally and vertically aligned andfully engaged with the respective end faces 80a of complementary opticalfibers 80 mounted in the disposable member 44.

As best seen in FIG. 10 and the details provided in FIG. 10A and 10B,with respective optical fibers 53 and 80 aligned, and respective endfaces 53a and 80a fully engaged, electrical contact between thedisposable member 44 and the non-disposable member 42 of the connector40 is achieved through the connection between contacts 103a and 103b onthe member 44 and the contacts 38 provided in the connector enclosure20. The engagement of electrical contacts 103a and 103b on thedisposable member 44 with the contacts 38 in the enclosure 20 alsoprovide a vertical upward spring force that assures proper seating ofthe disposable member 44. The contacts 103a and 103b on the disposablemember 44 complete electrical contact between the non-disposable member42 and the disposable member 44, and the latching members 84 of thespring 82 engage complementary latching elements 30a provided in therear wall 30 of the connector enclosure 20 to secure the disposablemember 44 in place in the fully aligned position of the fiber opticconnector 40.

As shown in the detail of FIG. 10A, the end faces 53a,80a of the opticalfibers 53,80 are parallel to each other, but at an oblique angle withrespect to the respective parallel axes thereof. In the preferredembodiment, the respective end faces are each disposed about 20° fromthe vertical. Further, the non-disposable glass (0.0096D) optical fiber53 is larger in diameter than the disposable plastic (0.0046D) opticalfiber 80.

A ray propagating along the non-disposable optical fiber 53 toward thefiber interface at an angle from its axis will strike the interface,producing a reflected component and a transmitted component ofnormalized amplitude. Because the angle at the fiber interface is chosento minimize unwanted reflections and to maximize data transmissions, forvirtually all rays within the optimum angle of the fiber interface, thereflections from the fiber interface will not be transmitted along theoptical fibers 53,80 but will be propagated into a cladding surroundingthem.

Since the beveled interface is effective in suppressing reflectersignals transmitted along the non-disposable optical fibers 53, it canbe made larger than the disposable optical fiber 80 without creating asignificant reflected signal.

With the connector 40 fully assembled, the enclosure cover 29 (FIG. 2)is placed on the enclosure 20. A rear end 121 of the cover 29 is bondedto the connector enclosure 20 using a suitable adhesive. The cover 29 ishinged at 122 with a front cover portion 123 overlying the main bodyportion 22 of the connector enclosure 20. Latching members 124 extenddownwardly from the front cover portion 123 to engage the respectiveinner walls 25 and 26 of the connector enclosure 20 to secure the cover29 in a closed position on the main body portion 22 of the connectorenclosure 20.

Having described a preferred embodiment of the present invention, itshould be understood that other embodiments could be defined within theclaims which set forth the invention. For example, the need to preciselyalign optical fibers, which may be as little as five thousandths of aninch (0.005") in diameter, indicates that the apparatus herein definedfor use with a cable assembly having multiple optical fibers would beequally useful in connecting a single optical fiber at the fiberinterface of the connector. Further, the dimensions of the respectiveoptical fibers mounted on the non-disposable and disposable members ofthe connector are not limited to the dimensions recited for thepreferred embodiment of the present invention.

We claim:
 1. A fiber optic connector comprising first and second opticalfibers, the first optical fiber having a beveled end face, the secondoptical fiber having a complementary beveled end face; andmeans foraligning said first and second optical fibers at a fiber interface, saidalignment means comprising: first engaging means for enabling therespective fiber end faces to abut at an angle at the interface, saidfirst engaging means comprising a U-shaped hollow non-disposable memberof the connector having a base, a pair of forwardly extending legsdisposed on opposite sides of the base with a front face of thenon-disposable member disposed between the forwardly extending legsthereof, the front face inclined to provide a ramp, the end face of thefirst optical fiber mounted in said front face, and a disposable memberof the connector having a complementary inclined front face, the endface of the second optical fiber mounted in said complementary frontface; a vertical aligned position for the connector; a verticalreference surface associated with the first optical fiber, and avertical reference node associated with the second optical fiber, saidvertical reference surface cooperative with said vertical reference nodeto align the respective fiber end faces at the vertical aligned positionfor the connector; a horizontal aligned position for the connector; ahorizontal reference surface associated with the first optical fiber,and a horizontal reference nodule associated with the second opticalfiber, said horizontal reference surface cooperative with saidhorizontal reference nodule for aligning the respective fiber end facesat the horizontal aligned position for the connector; and retainingmeans for holding said first and second fiber end faces in abutting andfull engagement at the fiber interface in a fixed aligned position, inwhich the vertical aligned position is coincident with the horizontalaligned position for the optical fibers of the connector.
 2. A fiberoptic connector as claimed in claim 1 wherein the fiber interface isdisposed at an angle of 15 to 30 degrees from a vertical plane at theinterface of the connector.
 3. A fiber optic connector as claimed inclaim 2 wherein a pad having an opening therein to receive the discreteoptical fibers is provided on the non-disposable front face, the padbeveled at the same angle as the end face of the first optical fiber. 4.A fiber optic connector as claimed in claim 1 wherein the non-disposableconnector member includes opposite side walls, said non-disposable frontface includes an inclined mid-portion disposed between said side walls,at least one of the side walls includes a notch adjacent the inclinedmid-portion disposed somewhat above a mid-plane of the side walls of thenon-disposable connector member, a first vertical side wall of the notchdisposed adjacent the inclined mid-portion to define a horizontalreference surface for the end face of the optical fiber disposed in thenon-disposable connector member.
 5. A fiber optic connector as claimedin claim 4 wherein the notch includes a horizontal side wall, transverseto the vertical side wall, said horizontal side wall defining a verticalreference surface for the end face of the first optical fiber disposedin the front face of the non-disposable connector member.
 6. A fiberoptic connector as claimed in claim 5 wherein the notch providing thehorizontal and vertical reference surfaces is tapered at a forward endto facilitate movement of the disposable member into the non-disposablemember toward the fixed aligned position for the assembled connector. 7.A fiber optic connector as claimed in claim 1 wherein the front face ofthe disposable connector member includes forwardly placed wear surfaces,which first engage the front face of the non-disposable connector memberwhen the disposable member is moved toward the non-disposable member foralignment.
 8. A fiber optic connector as claimed in claim 7 wherein thefront face is bounded by opposite forward lateral edges of thedisposable connector member, and the horizontal reference node ismounted on one forward lateral edge and the compressible crush rib ismounted on an opposite forward lateral edge, the reference node servingto engage the horizontal reference surface of the non-disposable member,the crush rib to engage an opposite side wall thereof, and guide thedisposable member to a terminal horizontal reference position defined atthe intersection of the horizontal and vertical reference surfaces ofthe connector.
 9. A fiber optic connector as claimed in claim 8 whereinthe front face is bounded on opposite ends by respective side walls of amain body portion of the disposable connector member, and the respectiveupper surfaces of said side walls have mounted thereon, adjacent thefront wall, a reference nodule, the reference nodule to engage thevertical reference surface of the non-disposable member at a terminalvertical reference position defined at the intersection of thehorizontal an vertical reference surfaces of the connector.
 10. A fiberoptic connector as claimed in claim 1 wherein the retaining meansincludes a connector enclosure, with the disposable and non-disposableconnector members nested therewithin, and a spring integral with therear end of the disposable member the spring engaging the connectorenclosure to secure the disposable and non-disposable members in a fixedaligned position of the optical fibers in the connector.
 11. A fiberoptic connector as claimed in claim 10 wherein the connector enclosureincludes registration slots in respective side walls thereof forreceiving a complementary flange provided at the outer end of thenon-disposable connector member.
 12. A fiber optic connector as claimedin claim 11 wherein the flange associated with the non-disposable memberincludes registration nodes for engaging the slots in the connectorenclosure to position the non-disposable member at a precise forwardposition within said enclosure, with the engagement of the base of theflange with a transverse slot provided between the side slots defining aregistration position for retaining the non-disposable member in a fixedvertical position within the enclosure.
 13. A fiber optic connector asclaimed in claim 12 wherein a pair of parallel slots adjacent respectiveside walls of the connector enclosure engage the transverse slotreceiving the base flange of the non-disposable member to definerespective openings in a base wall of the connector enclosure, theopenings to receive electrical conductors associated with a cableassembly retaining the optical fibers of the connector.
 14. A fiberoptic connector as claimed in claim 13 wherein a side channel associatedwith the connector enclosure receives reinforcing fibers of the fiberoptic cable assembly mounted in the non-disposable member of theconnector, the reinforcing fibers bonded in said side channel.
 15. Afiber optic connector as claimed in claim 14 wherein the connectorenclosure includes electrical contacts connected to the non-disposablemember of the connector, and the disposable member of the connectorincludes contacting fingers having respective electrical connections,such connections engagable with the connector enclosure, and alignmentof the respective end faces of the optical fibers at the fiber interfacein the fixed aligned position within the connector enclosure alsoelectrically connects the disposable and non-disposable members of theconnector.
 16. A fiber optic connector as claimed in claim 15 whereinthe contacting fingers are biased to urge the end face of the secondoptical fiber against the end face of the first optical fiber to thefixed aligned position of the assembled connector.
 17. A fiber opticconnector comprising a first plurality of first optical fibers, eachfirst optical fiber of said first plurality having a beveled end face;asecond plurality of second optical fibers, each second optical fiber ofsaid second plurality having a beveled end face complementary to an endface of a corresponding first optical fiber of said fist plurality; andmeans for aligning respective said first and second optical fibers at afiber interface of the connector, said alignment means comprising: firstengaging means for enabling the respective end faces of each first andsecond fiber of said first and second pluralities to abut at an angle atthe interface, said first engaging means comprising a non-disposablemember of the connector having opposite side walls, a front facedisposed between said side walls and inclined at a mid-portion thereofto provide a ramp, each opposite side wall including a notch adjacentthe connector interface at the inclined mis-portion and disposedsomewhat above a mid-plane of the side walls of the non-disposableconnector member, each notch including a first vertical side walldisposed adjacent the inclined mid-portion to define a horizontalreference surface, the end face of each first optical fiber disposed inmounted said front face of the non-disposable connector member and ahorizontal side wall, transverse to the vertical side wall and extendingtoward the inclined mid-portion of said front face, said horizontal sidewall defining a vertical reference surface for the end face of eachfirst optical fiber disposed in the front face of the non-disposableconnector member, each notch providing the horizontal and verticalreference surfaces being tapered at a forward end to facilitate movementof the disposable member into the non-disposable member; a horizontalaligned position for the connector; a horizontal reference nodeassociated with said second optical fibers, said horizontal referencesurface cooperative with said horizontal reference node for aligning therespective fiber end faces at the horizontal aligned position for theconnector; a vertical aligned position for the connector; a verticalreference nodule associated with said second optical fibers, saidvertical reference surface cooperative with said vertical referencenodule to align the respective fiber end faces at the vertical alignedposition for the connector; and retaining means for holding eachrespective first and second fiber end face of said first and secondpluralities in abutting and full engagement at the fiber interface in afixed aligned position for the assembled connector, in which thehorizontal aligned position is coincident with the vertical alignedposition for the optical fibers of the connector.
 18. A fiber opticconnector as claimed in claim 17 wherein the fiber interface is disposedat an angel of 15 to 30 degrees from a vertical plane at the interfaceof the connector.
 19. A fiber optic connector as claimed in claim 18wherein a pad having an opening therein to receive each first opticalfiber is provided on the non-disposable front face, the pad beveled atthe same angle as the end face of each first optical fiber.
 20. A fiberoptic connector as claimed in claim 17 wherein the front face is boundedby opposite forward lateral edges of the disposable connector member, asubstantially incompressible, horizontal reference node is mounted onone forward lateral edge adjacent the connector interface, and acompressible crush rib is mounted on an opposite forward lateral edge,aligned with said reference node, the reference node to engage a firsthorizontal reference surface of the non-disposable member, the crush ribto engage a second horizontal reference surface thereof, tocooperatively guide the disposable member to a terminal horizontalreference position defined at the intersection of the horizontal andvertical reference surfaces of the connector.
 21. A fiber opticconnector as claimed in claim 20 wherein the front face is bounded onopposite ends by respective side walls of a main body portion of thedisposable connector member, and the respective forward upper surfacesof said side walls have mounted thereon, adjacent the front wall, at theconnector interface, a reference nodule, each reference nodule to engagea respective vertical reference surface of the non-disposable member ata terminal vertical reference position defined at the intersection ofthe horizontal and vertical reference surfaces of the connector.